Method of winding coils



July 30, 1929. s. c. WILEY METHOD OF WINDING COILS Filed Nov. 30, 1926 Patented 1a,; 30, 1929.

' UNITED STATES PATENT OFFICE.

'SCHUYLEB co rAx WILEY, or LA GRANGE, rumors, ASSIGNOR TO wEsr'Ean ELEC- TBIC 001mm, mdoarona'rnn, ornnw' YORK, N. Y., A ooarona'rron. or new im'rnon or wn w'nme coILs.

Application fl1ed 1Tovemlier-80,192 8. Serial 1%. 151,757.

, This invention relates to a method of wi'ndpractice in some instances to connect an uninsulated terminalor stranded leadin wire to the end of'the enamel insulated wire preliminary to starting the wind ng ofthe'coil.

The :t'ree end of the'le'addh wire is then inserted through anjaperture provided in one of the spool heads of the core and the portion of the lead extending from the inner face of the spoolhead is covered with'paper or other suitable insulating material, after which the windingof the .coil is continued in the usual manner. In practicing this method of winding electrical coils a very high degreeof-care and skill is required in the winding of the coil in order to eliminate the possibility of the first oneor two turns of enameled wire in, the first .two or three'layers from working their way downwardlyalong theinner side of'the spool head and coming into cont-act .with' the bare lead-in wire,

which condition may, in some instances, result inportions .of the insulating enamel becoming-removed from the enameled wire,

thus rendering it possible for one or more i3o' layers of the coil being shorted from the remander of the coil. i -The principal object of method of winding electrical coils w erein the possibility of deleterious short circuits due to the. above causes is eliminated. I

In order to attain this object, in accord .ance with the features of the invention, the

uninsulated terminal or lead-in wire is con-. ao nected to the enamel insulated winding material in theusual manner and then covered with paper or other suitable insulatingimaterial. Atthe starting of the winding operation, the first few turns of the insulated wire 415' are superimposed upon the terminal or lead-- in'wire adjacent the inner face of the spool head, after which the winding of the 601i.

this invention is. the provision of an improved and simplified "a coil which has been partially wound in accordance with the improved method;

ig. 2'is a fragmentary-longitudinal sec- ,tion of the coilshown in Fig; l;

Fig. 3 ,is an elevational view, partly in section, of a completed coil, and

Fig. 4 is a detail "view illustrating the method of insulating the lead-in wire prehmmary to starting the winding of the coil. Referringnow to the drawingin detail,

in which similar reference numerals refer to.

like parts throughout the several views, the. numeral 10 indicates a core, composed of magnetic material, .and having attached thereto at'each end a spool head ll-which may be of metal. The core 10 .is preferably insulated-by one or more vlayers of paperor other suitable insulating'material l2, and one or more insulating washers 13 are usually pi'ovided'on the inner faces of the spool heads Before starting the winding of the coil a suitable length of a bare stranded lead-in wire 14 is connected to the end of the enamel insulated winding wire 15, as best shown in Fig. I is an enlarged fragmentary View of Fig. 4'. The free end of the lead-in wire is then insertedthrou'gh anaperture provided 1n the spoolhead 11 adjacent to the core 10 and a strip of paper 16 (Fig. 4) for other suitable insulating material is wrapped around the portion of the lead-in wire extending from the inner face of the spool head. The paper insulated lead-in wire is then-wrapped around the. core 10 adjacent to the spool ead through which it enters the spool. Before starting the usualwinding of the coil several turns of the enamel'insulated I winding material arewrapped around the lead-in wire adjacent tothe, spool head;

through which the lead-in wire enters the spool, as best shown in Fig. 2. The winding ofthe coil is then continued in the usual manner., Sheets or'strips 17 of paper or other suitable insulating material may be inserted between each layer of wire as the coil is built up and the completed coil is usually provided with an outer covering 18 as shown in Fig. 3.

In the manufacture of electromagnetic coils in. accordance with the present-invention, the possibility of deleterious short circuits due to the enamel insulated wire im-. p'inging against and electrically contacting with the bare lead-in wire is practically elim-' ,inated. It for any cause one of the first few turnsof the enamel insulated wire comes in contact with the bare lead-in wire; it could only result in a comparatively short length of Moreover, the possibilityqof one or more layers of wire being shorted from the coil is eliminated. sinceithe enameled wire in the above applied layers is prevented from eon tacting with the lead-in wire due to the intermediate turns of enameledwire which have been 1 superimposed jupon the lead-in wire before starting the winding of the'coil. Thus it is apparent that bypracticing the present invention coils of uniform electrical characteristi'csinay be very-readily manufactured,

' it only being necessary to insure that approximatc y the required amount of winding material is used.- Furthermore,-the possibility ofcoilsma-nufacturedby this method becom ing unsuitable for use due to deleterious short circuits caused by th'ebare lead-inwire con- I layers of the insulated conducting material tacting with the enameled wire ofthe upper.

layers of the coil is eliminated. i

Whatis claimed is:'

1. A method of winding electrical coils upon headed spools, which consists in elec-. 'trically connecting an ,uninsulated lead-in' wire to an end of a supply. of winding material, passing the end of the lead-in wire through a spool head, superimposing a pluwire so covere rality of layers of winding materlal upon the lead-in wire, and upon each other adjacent -'to" said spool head, and thenstarting the winding of the first layer of the coil.

2A method of winding electrical; coils upon headed spools, which consists in,'elec trically connecting an uninsulated lead-in wire to an end of a sup 1y of insulated wind ing material, passing t e end of the lead-in wirethrough a spool head, covering the inner portion. of the leadain w re ,with'insulating material, wrapping the portionvofthe lead-in around the core adjacent the said spool head, superimposing aplurality of layers of the insulated winding material upon the lead-in wire and upon eachother adjacentto said spool head, and then starting the vwinding of the first layer of the coil.

3. The -method of winding electrical coils,- which consists in electrically connecting an uninsulated lead-in wire to an 'end of a supply of insulated winding material, wrapping a portion of the leadn: wire around one end of a core, superimposing a plurality of layers of the insulated winding material upon the wrapped-portion of the lead-in wire and upon each other, and then startingthe winding'of the first layer of the coil.-' 7

4. A'method of winding electrical. coils I upon headed spools, which consists in electrically connectingan uninsulatedTea-d-in wire to an end of'a supply ofinsulated conductingmaterial, passing the outer'end' ortion'of the lead-in wire through a head 0 the spool, covering the inner portion'of the leadin wire with a sleeveof insulating material, wrapping theportion ofthe lead-inwireso covered aroundthe core adjacent to the said,

spool head, superimposing a plurality of upon thelead-in wire at the junction between the insulating sleeve and the inner face of the adjacent spool head, and then starting the winding of the first layer of the coil.

5. A method of winding electrical coils upon "a core, which consists in electrically connecting an uninsulated. stranded lead-in wire to an' enamelled wire, insulating the lead-in lead-in wire around-the core near one'end thereof, applying several indiscriminately arranged layers of "ena'melled wire on said lead-in wire at the end of the insulation thereof opposite, the end in contact with the enwire and the junction with the enamelled .wire, wrapping the insulated .portion of the amelled wire to insulate any exposed portion of the lead-inwire, and thereafter applying i1 additional layers to, constitute the co a In witness whereof, I hereunto subscribe 

